Method for forming wall board panels



Oct. 17, 1961 L. E. MEDAL ET AL 3,004,261

METHOD FOR FORMING WALL BOARD PANELS Filed Aug. 22, 1957 2 Sheets-Sheet 1 INVENTORS .ZeOIL 15'. JZedaLfa Hem-g Z'Pores.

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ATTORNEY Oct. 17, 1961 1.. E. MEDAL ETAL 3,004,261

METHOD FOR FORMING WALL BOARD PANELS Filed Aug. 22, 1957 2 Sheets-Sheet 2 I /B\ /E\ INVENTORS 4770mm r.

3,004,261 Patented Oct. 17, 1961 3,004,261 METHOD FOR FORMING WALL BOARD PANELS The present invention contemplates a method and apparatus for the formation or construction of building panels such as those constructed of fiberboard sheets.

In the construction of fiberboard wall panels, it is usually the practice to interpose a corrugated strip of fiberboard or other material between two layers or skins of fiberboard and to secure the crowns of the corrugated filler or spacing core by stapling operations. It is desirable, moreover, that the staples be driven into the skins from the exterior surface thereof so as to present no objectionable prongs, however, when the skins are applied to opposing sides of the corrugated filler or spacer, it is difiicult to determine the exact location of the underlying crowns for the application of the staples or other securing devices. An important object of the present invention, therefore, is to provide means of comparatively simple construction whereby to facilitate the assemblage of the skins upon the corrugated filler and to exactly locate the point of contact between the spaced skins and the underlying crowns of the filler sheet in order that an operator may definitely bring about a proper and secure stapling operation.

A further object of the invention is to provide apparatus for application to the filler strip and a skin to definitely determine the location of securing staples between the skin and an underlying crown, together with backing means to insure proper stapling of the skin and the underlying crown without disturbing the relative relationship between the filler and the skin.

A still further object of the invention is to provide an anvil structure of such character as to be accommodated within the valley of the corrugated filler and to bear against the crown thereof to constitute a proper holding surface against the crown during the stapling operation.

A further object of the invention is to provide a method of assembling the sheets or skins with the corrugated filler between them by which the assemblage of these elements may be speedily and effectively accomplished in the production of the completed rigid panel.

With the foregoing objects in view, the invention resides in the novel construction, combination and arrangement of parts, all as will be described more fully hereinafter, illustrated in the drawing, and particularly pointed out in the claim.

In the drawings:

FIG. 1 is a perspective view of one end of the anvil structure and straight edge associated therewith utilized in carrying out the invention,

FIG. 2 is an enlarged transverse sectional view taken through the device as illustrated in FIG. 1 and illustrating its application to the wall board panel structure,

FIG. 3 is a side elevation, on a reduced scale, of the structure shown in FIG. 2, illustrating the straight edge in proper position with a conventional stapling device in proper position for bringing about the stapling operation, and

FIG. 4 discloses end elevations showing the several steps in the method here employed in assembling and securing the elements of a panel together.

As has been before stated, the panels to be constructed comprise skins or flat sheets 5 and 6 maintained securely together in spaced parallelism by a substantial corrugated filler or spacing core indicated at 7, shown more particularly in FIG. 3 of the drawing. The skins, as well as the filler, may be formed of fiberboard or any other similar or like material. The corrugations provide valleys 8 and crowns 9, the inner faces of the spaced skins being rigidly attached to the crowns throughout the length and breadth of the completed panel to be formed, and usually the skins are attached to the underlying crowns by means of staples indicated at 10 in FIG. 2 of the drawing.

In the assembly of this structure, the corrugated filler of the proper length and breadth is laid flat upon a table for the support represented at 11, sub-Figure B in FIG. 4, after which a skin 5 of fiat fiberboard corresponding substantially to the length and breadth of the filler is laid upon the latter with its undersurface in engagement with the crowns 9 thereof, as in sub-Figure C of FIG. 4. Into each of the valleys of the filler core is inserted an anvil as shown in FIG. 1 of the drawings. This anvil comprises a supporting base 12 of such length as to project beyond the ends of the filler, and has upon its upper surface rigidly connected thereto an anvil base 13 having its upper face shaped so as to conform substantially to the unders-urface of the crown of the filler member. The depth of this anvil structure corresponds substantial-1y to the transverse dimension of the filler core, and while resting upon the base 11, in support of the crowns, the first skin 5, is laid flat upon the filler so as to contact the said crowns. However, with the filler thus completely covered by the skin, it is difficult to determine the precise location of the underlying crowns, and means are provided to definitely locate the precise point of contact between the crown and the skin, in order that the staples may be accurately placed.

With reference to FIG. 1 of the drawings, it will be observed that the supporting base 12, which projects beyond the end of the anvil base 13, is provided with openings 14 to receive a pin 15 rigidly secured to and depending fromthe end of a straight edge indicated at 16. While only one end of the supporting base is here illustrated, it will be observed that each end of the base will be similarly provided with openings 14 for the reception of the guide pins 15. The openings are so located with respect to the anvil base that the adjacent edge of the straight edge 16 will overlie the median portion of the anvil itself, which is directly beneath the crown 9 of the filler. With the position of the anvil thus definitely indicated, staples may be driven with the stapler 17 in the usual manner, the anvil and the supporting base constituting a support to maintain the core against any possibility of crushing, and also aifording means whereby the ends of the staple may be clinched beneath the underlying crown. After the staples in sufiicient number have been applied so securely hold the skin 5 to the crowns of the underlying core, the anvil structure may be removed by being longitudinally slid from Within the core. With one skin properly attached in the manner described to the underlying crowns of the filler, the opposite sheet 6 is applied to the reverse face of the filler, the anvil structure and straight edge being inserted in the several valleys and the stapling operations above described carried out so as to bring about secure attachment of the other skin to complete the operation.

The construction of the anvil here illustrated discloses two parts rigidly secured together, but it will be understood that the anvil may be of unitary structure if desired. It will be apparent that by use of the anvil and straight edge in the manner described, the accurate location of the underlying filler crowns may be readily determined and the filler and skill will be held or supported securely during the stapling operation without danger of any crushing or distorting eifects.

With reference to FIG. 4 of the drawing, sub-FIG- 3 URES A, B, C, D, E and F will be described; these subfigures disclosing the several steps in the method by which the wall board or panel is formed.

In sub-FIGURE A, supporting bases 12 with their anvil heads 13 are arranged in spaced parallelism upon the table or platform A, after which the filler core 7, here in flat form, is placed upon the said anvils. Mounted above the filler 7 is a gang of similar supporting bases and anvils 1213 disposed equi-distance between and parallel with the upstanding anvil structures resting upon the base. When the overhead gang of anvil structures is lowered, as shown in sub-FIGURE B, the flat filler 7 is depressed to bring about the desired crowns and valleys of the sheet. When in this position (sub-FIG. C) the first skin 5 is applied to the crowns 9 of the core, whereupon the stapling action is performed to secure the skin 5 to the crowns. When this has been accomplished, the upper gang of anvil structures is raised (sub-FIG. D) carrying with it the filler core 7 and the attached skin 5. The entire structure is then reversed and lowered to the position shown in sub-FIG. E with the upper gang of anvil structures disposed above those resting upon the base 11. The second skin 6 is then applied to the upstanding crowns 9 in the manner heretofore described, after which the stapling operation is carried out, bringing about the finished wall panel shown in sub-FIG. F of the drawings. The anvil structures may then be withdrawn from the valleys of the filler and the operation is complete.

It is apparent from this description that the structure here described for definitely locating the point of contact between the flat skin and the underlying filler crowns enables these elements to be quickly and easily secured together by the desired and approved securing means. The straight edge is quickly and easily applicable to the anvil srtucture to definitely locate the position of the hidden anvil and may be used to properly locate markings for the application of staples or other securing devices. By the method outlined, panels of this character may be quickly and readily assembled at material saving of labor and time and with the assurance of the production of a uniform and satisfactory panel.

We claim:

The method of forming a panel comprising arranging a plurality of fixed anvils in spaced parallelism, applying a flat core sheet to the upper surfaces of said anvils and in resting engagement thereon, lowering a second set of spaced parallel anvils upon said core member between said primary anvils to depress said core between the latter and to provide spaced parallel oppositely directed crowns in said core, applying a flat skin to one side of said core and securing the same to the underlying crowns, removing said core, skin and second set of anvils from said fixed anvils, reversing the same and resting the skin upon said fixed anvils with the second set of anvils aligned therewith, applying a second flat skin to the upper surface of said core in engagement with the spaced crowns thereon, securing said second skin to said crowns, and removing said second set of anvils from between said skins.

References Cited in the file of this patent UNITED STATES PATENTS 1,173,697 Allan Feb. 29, 1916 1,430,996 Horlin Oct. 3, 1922 2,123,609 Mitchell July 12, 1938 2,746,139 Van Pappelendam May 22, 1956 2,828,235 Holland Mar. 25, 1958 2,832,104 Maryanski Apr. 29, 1958 FOREIGN PATENTS 167,645 Australia Aug. 27, 1953 

